30 Jan, 2026
Coir mats are becoming increasingly popular due to their durability, biodegradability, and clean, eco-friendly appearance. Made entirely from natural coconut fiber, these mats are widely used in homes, gardens, outdoor spaces, and even construction projects.
At Phu Hao Factory, we produce every high-quality coconut mat through a carefully controlled and systematic process. In this blog, we will explore our factory and learn about each step of the coconut mat production process, from raw coconut husks to finished products ready for export.
The primary raw material for coir mats is ripe coconut husks, sourced directly from Ben Tre Province, Vietnam’s largest and most renowned coconut-growing region.
We select only mature husks because their fibers are stronger and more durable, ensuring the final mats meet high-quality and performance standards.
After harvesting, the husks are thoroughly cleaned and sun-dried naturally. This traditional drying method preserves the fibers’ natural toughness and flexibility while preventing brittleness.
Natural drying also makes the fibers safer and easier to process in later stages.
The dried husks are then fed into a fiber-loosening machine, which gently separates the fibers while removing impurities such as dust, coconut residue, and weak fibers.
The result is clean, soft, and uniform fiber ready for twisting.
Next, the loose fibers are twisted into small, round fiber yarns using a twisting machine. These yarns must meet strict requirements for:
This step plays a crucial role in determining the coir mat’s overall durability.
To create a stronger weaving material, eight small fiber yarns are combined into one large coconut fiber string.
The number of yarns can be adjusted depending on customer specifications and end-use requirements.
Once the fiber strings are ready, mat weaving begins using one of two methods:
After weaving, each mat undergoes careful manual inspection. Workers check the weave structure, fix minor imperfections, and remove excess fibers to ensure every mat meets Phu Hao’s quality standards.
To enhance appearance and performance, the mats are heat-treated. This step:
Heat treatment also adds a light protective layer, helping mats perform better in humid environments.
Packaging methods vary depending on product size and application:
After labeling and sorting, products are stored in the warehouse or prepared for shipment.
From Coconut Waste to Sustainable Value
Phu Hao employs a meticulous 9-step production process to transform rough coconut husks, once considered agricultural waste, into high-quality, eco-friendly coir mats suitable for residential, commercial, and construction applications.
By combining carefully selected raw materials with modern manufacturing techniques and skilled craftsmanship, Phu Hao delivers products that are not only durable and functional but also reflect a strong commitment to sustainability and eco-friendly production.
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📧 Email: phuhaogroup@gmail.com / henry@phuhaogroup.com
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